Disposable cardboard pan, end forms, and inserts



Dec. 25, 1956 EMls 2,775,019

DISPOSABLE CARDBOARD PAN, END FORMS AND INSERTS Filed Feb. 2, I953 3 Sheets-Sheet l 2a 24 A Thomas E Bemis )))E $1); INVENTOR 4 F I g. 3

14 J BY T. F. BEMIS Dec. 25, 1956 DISPOSABLE CARDBOARD PAN, END FORMS AND INSERTS Filed Feb. 2, 1953 3 Sheets-Shae? 2 Thomas F Beml's Fig. 7

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DIPOSABLE CARDBOARD PAN, END FORMS AND INSERTS Filed Feb. 2, 1955 3 Sheets-Sheet 3 y I. I \/26 I40 Thomas E Bemis INVENTOR.

United States Patent DISPOSABLE CARDBOARD PAN, END FORMS, AND INSERTS Thomas F. Bemis, Plainville, Kans.

Application February 2, 1953, Serial No. 334,531

4 Claims. (Cl. 25--131.5)

This invention relates in general to forms for concrete constructions, and more specifically to forms for forming concrete floors of the T-beam type.

At the present time there is in common use forms of the pan type which are formed of steel or other suitable metals. These forms are relatively expensive and of a rigid construction whereby their lengths cannot be easily modified. Therefore, it is necessary to retain a large quantity of such pans on hand, such pans being of different widths, heights, lengths, etc., so as to permit various types and heights of floors to be poured. Also, due to their rigid construction the pans are not easily shipped. A further disadvantageous feature of the pans now in use is the relatively high initial cost and the fact that they must he removed from a concrete floor after the same has been poured.

It is the primary object of this invention to provide an improved form for concrete floors and the like which is formed of a relatively inexpensive material, such as f1- brous material, and more particularly cardboard whereby the same may be discarded after a single use if desired and still be economically feasible.

Another object of this invention is to provide an improved form for concrete in the form of an elongated pan which is formed of a material which may be easily cut with conventional hand saws whereby the over-all length of the pan may be varied as desired to fit different types of construction.

Another object of this invention is to provide an improved form for concrete work in the form of an inverted pan, said pan being so constructed whereby the same may be shipped in a flat state and quickly and conveniently assembled so as to reduce the shipping cost of the same.

Another object of this invention is to provide an improved combination floor and ceiling construction which includes a concrete floor of the T-beam type which has connected to the bottoms of the concrete beam expanded steel lath forming reinforcing for a ceiling, the lath being secured to the concrete floor during the course of pouring the same.

Another object of this invention is to provide an improved combination fioor and ceiling construction'for a building. including a concrete floor of the T-beam type which is formed by utilizing pans for forms, said pans being left in place and having their bottoms closed by a ceiling including a reinforcing mesh secured to the concrete beam, the form being subdivided by reinforcing members for the same to form dead air spaces and thereby increase the insulation characteristics of the floor and ceiling construction.

A still further object of this invention is to provide an improved method of forming a combination floor and ceiling construction, said method including the steps of erecting a supporting framework, placing reinforcing mesh over the supporting framework, placing forms over the reinforcing mesh and securing the forms to the supporting framework, placing concrete between and over the "ice forms, removing the supporting framework and applying cementitious material to the reinforcing mesh to form a ceiling.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout, and in which:

Figure l is a vertical sectional view through a concrete floor of the T-beam type and shows the same in one step of its formation in accordance with the above outlined objects of the invention, a portion of a supporting framework for forms of the floor being broken away and omitted;

Figure 2 is a perspective view of a preferred form of pan utilized as a form for the construction of the floor of Figure 1;

Figure 3 is an enlarged fragmentary vertical sectional view taken substantially upon the plane indicated by the section line 33 of Figure 2 and shows the manner in which a reinforcing member of the pan is secured to a channel-shaped member forming the exterior thereof;

Figure 4 is an exploded perspective View on a reduced scale of one end of the pan of Figure 2 and shows the same preparatory to the connection thereof with an end form;

Figure 5 is a transverse vertical sectional view on an enlargedscale taken substantially upon the plane indicated by the section line 5-5 of Figure 4 and shows a cross section of the pan and including inserts telescoped therein for connecting an end-form thereto;

Figure 6 is a transverse vertical sectional view of a modified form of pan which utilizes a pair of reinforcing members; I

Figure 7 is an end view of a blank for forming the pan of Figure 2;

Figure 8 is a fragmentary perspective view of the pan and showing the same having secured thereto an elongated double tapered end form, portions of the end form being broken away in order to show the position of an insert securing the same to the pan;

Figure 9 is a fragmentary perspective view similar to Figure 8 and shows the pan connected to an elongated single taper end form;

Figure 10 is an end elevational view of the end form of Figure 8 and shows the general outline of the same; and

Figure 11 is an end elevational view of the end form of Figure 9 and shows the general appearance of the same.

Referring now to Figure 2 in particular, it will be seen that there is illustrated a preferred form of pan construc tion to be utilized as a form in the pouring of concrete floors of the T-bearn type, the pan construction being referred to in general by the reference numeral 10. The pan 10 includes a channel-shaped member which is referred to in general by the reference numeral 12 and a generally V-shaped reinforcing member which is referred to in general by the reference numeral 14.

The channel-shaped member 12 includes an upper web 16 which has integral with the side edges thereof depending flanges 18. The flanges 18 are slightly outwardly and downwardly flared and terminated in outwardly directed wings 20 which are disposed in a common plane and which are in spaced parallel relation to the web 16.-

The reinforcing member 14 includes a pair of downwardly and outwardly directed intermediate portions 22 which terminate in outwardly directed flanges 24.

The reinforcing member 14 is securedat its center to the underside of the web 16 at its center by a plurality of longitudinally aligned fasteners which may be in the form of staples 26 as is best illustrated in Figure 3. The portions 22 slope downwardly and outwardly from the web 16 to the lower edges of the flanges 18 and the flanges 24 underlie the Wings 20. The Wings 20 are removably secured to the flanges 24 by fastening means in the form of spaced staples 21.

Referring now to Figure 7 in particular, it will be seen that when the pan is originally formed and packaged for shipment the channel member 12 and the reinforcing member 14 are in the form of flat sheets secured together along their center lines by the staples 26. It will be understood that the sheets forming the channel member 12 and the reinforcing member 14 are provided with suitable fold lines to facilitate the bending thereof into the relative shapes illustrated in Figure 2. It will also be understood that the pans 10 are actually converted into the form illustrated in Figure 2 from the form illustrated in Figure 7 on the job immediately prior to their positioning on their supporting framework.

Referring now to Figure l in particular, it will be seen that there is illustrated a combined ceiling and floor construction in an intermediate stage of manufacture. In the forming of the combined floor and ceiling construction there is first placed a suitable supporting framework 36 which is supported by a plurality of extensible supports 32. After the supporting framework 30 has been properly positioned, there is placed thereover a stretched expanded steel lath 34 whose purpose will be explained in more detail hereinafter. Then the pans 10 are properly positioned on the supporting framework 30 in overlying relation to the reinforcing lath 34 in their desired spaced relation. The pans 10 are secured to the supporting framework 30 by nails or other suitable fasteners 36 which pass downwardly through the apertures 28 in the wings and the flanges 24. The fasteners 36 also secure the reinforcing lath 34 to the supporting framework with the flanges 24, in combination with the framework 39, sealing the lath 34 against escape of concrete.

After the pans 10 have been properly placed, concrete is poured therebetween and over to form a floor construction of the T-beam type, the floor construction being referred to in general by the reference numeral 38. The floor construction 38 includes a floor slab 40 which overlies the pans 10 and depending ribs or beams 42 which are disposed between adjacent pans 10.

After the concrete of the floor construction 38 has set the supporting framework 30 and the supports 32 are removed and the floor construction 38 is self-supporting. Inasmuch as portions of the beams 42 interlock with the lath 34, it will be seen that the lath is supported by the beams 42. However, if the support is believed to be insufficient, the lath 34 may be initially provided with J fasteners 44 which project outwardly into the beams 42. After the supporting framework 39 has been removed, the lath 34 is coated with a suitable cementitious material (not shown) to form a ceiling construction (not shown).

It will be noted that the pans 10 are left in the floor construction 38 when the ceiling is being formed. While such a construction is not feasible with the present metal pans, when the pans 10 are formed of a suitable fibrous material, such as cardboard, their initial cost is relatively inexpensive and the costs of removing them from the floor construction may exceed their initial cost. By leaving the pans 10 within the confines of the floor construction 33, it will be seen that the insulation characteristics of the floor may be increased. It will be noted that the reinforcing member 14 divides the pan 10 into a pair of separate air spaces 46 and also forms in combination with the ceiling, which includes the reinforcing mesh 34, an air space 48. As is well known, the provision of numerous dead air spaces adds to the insulation qualities of a wall, floor and ceiling construction.

While there has not been illustrated the same, if desired plumbing or wiring may also be incorporated in the floor construction 38 at the time of its pouring. Such wires or piping which may be necessary may either pass through the pans 10, which may be easily cut, or may overlie the same and be supported thereby.

It will be understood that in the arranging of forms for a T-beam type floor construction there may be aligned a plurality of such pans 10. Also, it is necessary to close the ends of each row of pans to prevent the running of the concrete within the ends of the pans. Therefore, as is best illustrated in Figure 4, there is provided an end form which is referred to in general by the reference numeral 5d. The end form 50, like the pan 10, includes a channel-shaped member which is referred to in general by the reference numeral 52 and a V-shaped reinforcing member which is referred to in general by the reference numeral 54.

The channel-shaped member 52 includes a web 56 and a pair of outwardly flared flanges 58. The channelshaped member 52 also includes wings 60 which are integral with the lower edges of the flanges 58. It will be understood that the various components of the channelshaped member 56 have transverse dimensions identical with those of the channel-shaped member 12 of the pan It The reinforcing member 54 includes a pair of diverging portions 62 which terminate at their lower ends in outwardly directed flanges 64, the flanges 64 underlying the wings 60 and being secured thereto bystaples 65. The flanges 64 are also provided with aligned apertures 66 with similar apertures in the wings 60 for the reception of fasteners such as the fasteners 36. The reinforcing member 54 is secured to the underside of the web 56 by a longitudinal row of fasteners such as staples 68. The portions 62 slope downwardly and outwardly and terminate at the lower edges of the flanges 58 to form generally triangular spaces 70 which are of identical cross sections with the spaces 46 of the pan 10.

The end form 58 differs from the pan 10 in that it is of a relatively short length and one end of the same is closed by a downwardly and longitudinally sloping end wall 72. The end wall 72 coincides with downwardly and outwardly sloping edges 74 of the flanges 58 and terminates at its edges with a pair of inwardly directed flanges 76. The flanges 76 are secured to end portions of the flanges 58 by suitable fasteners 88. The fasteners being removable and in the form of rivets or bolts. The end wall 72 includes a lower outwardly directed flange 82 which is provided with a plurality of apertures 84 for receiving fasteners to secure the same to the supporting framework 38.

In order that the end form 50 may be conveniently secured to the pan 10, there is provided a pair of inserts which are referred to in general by the reference numeral 86 and which are best illustrated in Figures 4 and 5. The inserts 86 are triangular in cross section and of a size to be received within the spaces 46 and 70. As is best illustrated in Figure 5, the inserts 86 each includes a central portion 88 which underlies a web portion of either an end form or a pan, a downwardly directed outer portion 90 integral with one edge of the central portion 88, and a downwardly and outwardly sloping portion 92, the portion 92 being integral with the opposite edge of the central portion 88. The free edges of the portions 90 and 92 are in abutting relation with the triangular form of the inserts 86 being retained by the spaces in which they are disposed.

But it is desired to assemble a pan 10 and the end form 50, the inserts 86 are placed either into the end form or the pan and then the end form and pan are slid toward each other with the inserts 86 having ends thereof abutting against the end wall 72 of the end form. It will be understood that it is preferred that one end of each insert 86 be cut at a slope to facilitate abutment therewith with the end wall 72.

While the inserts 86 have been described for use in connecting an end form 50 to a pan 10, it will be understood that identical or similar inserts may be utilized to connect together adjacent pans.

When assembling a plurality of pans 10 and end forms 50, the combination of a number of whole pans and end forms may not equal the desired length of form. Inasmuch as the pans 10, as well as the end forms are formed of fibrous material such as cardboard, it will be seen that one or more of the pans may be easily sawed to provide a pan of a reduced length.

Referring now to Figure 6 in particular, it will be seen that there is illustrated a modified form of pan which is referred to in general by the reference numeral 94. The pan 94 is of a greater height than the pan 10 and requires greater reinforcement. The pan 94 includes a generally channel-shaped member 96 which has disposed therein a first reinforcing member which is referred to in general by the reference numeral 98 and a second reinforcing member which is referred to in general by the reference numeral 100.

The channel-shaped member 96 is elongated and includes a web 102 which is integral with depending diverging flanges 104. The lower ends of the flanges 104 terminate in outwardly directed wings 106.

The first reinforcing member 98 is also generally channel-shaped and includes a web 106 which directly underlies the web 102. The web 103 is of a less width than the web 102 and is secured thereto along its center line by suitable fasteners in the form of staples 110. The first reinforcing member 93 also includes a pair of spaced diverging, downwardly directed flanges 112 which are integral with edges of the web 108. The flanges 112 terminate in downwardly directed wings 114 which are in abutting relation with the inner surfaces of the flanges 104 intermediate their ends. The wings 114 are removably secured to the flanges 104 by suitable fasteners 116.

The second reinforcing member 100 is generally V- shaped and is secured at its mid-point to the web 102 by the fasteners 110. The second reinforcing member 100 includes a pair of downwardly and outwardly directed portions 118 which terminate with their intersections with the lower edges of the flanges 104. Integral with the portions 118 are outwardly directed flanges 120 which underlie the wings 106 and are secured thereto by spaced staples 121. It will be understood that the wings 106 and the flanges 120 are provided with aligned apertures (not shown) for the reception of fasteners such as the nails 36.

It will be seen that the construction of the pan 94 not only provides additional air spaces including triangular spaces 122 in which suitable inserts (not shown) may be inserted for connecting adjacent pans or inserts to pans. It will also be noted that when the fasteners 116 are removed the pans 94 may be flattened out in the form of a blank formed by three flat overlying sheets secured together by a line of staples 110. These three sheets will be provided with suitable fold lines to permit bending of the same to the shapes illustrated in Figure 6.

Referring now to Figure 9 in particular, it will be seen that there is illustrated a modified form of end form which is referred to in general by the reference numeral 122. The end form 122 is relatively long and is formed of a generally channel-spaced member 124 which has disposed within the interior of the same a reinforcing member which is referred to in general by the reference numeral 126. The reinforcing member 126 is secured to the channel-shaped member 124 by a longitudinal row of fasteners such as staples 128.

The channel-shaped member 124 includes a web 130 which is generally trapezoidal in outline, the free end of the web being narrower than the end thereof which is adapted to abut a pan 10. The end of the web 130 in height.

6 abutting the web 16 of the pan 10 is identical in width with the web 16. In fact, the cross section of the channel-shaped member 124 at the end thereof abutting the pan 10 is identical with the cross section of the channelshaped member 12.

The channel-shaped member 124 includes a pair of outwardly flared downwardly directed flanges 132 which are integral with side edges of the web 30. The flanges 132 converge inwardly toward the free end of the end form 122. The flanges 132 terminate at their lower edges in outwardly directed wings 134.

The wings 134 of the channel-shaped member 124 overlie outwardly directed flanges 136 of the reinforcing member 126.- It will be understood that the reinforcing member 126 at its end adjacent the pan 10 is a cross section identical with that of the reinforcing member 14. It will also be understood that the reinforcing member 126 decreases in width toward the free end of the end form 122 in the same manner as does the channel member 124. The wings 134 and the flanges 136 are secured together by spaced staples 137 and are provided with aligned apertures 138 for receiving nails or the like securing the same to a supporting frame.

The channel-shaped member 124 terminates in a downwardly and outwardly directed end wall 140 which is provided at its side edges with inwardly directed flanges 142 underlying in abutting relation the flanges 132. The flanges 142 are secured to the flanges 132 by suitable removable fasteners 144. The end wall 140 also termina-tes-at its lower end in an outwardly directed flange 146 to facilitate the securing of the same to a supporting framework. The flange 146 is provided with suitable apertures 148 for the reception of fasteners.

While it has not been clearly illustrated, it will be understood that the end form 122 is secured to the pan 10 by suitable inserts. The inserts will differ from the inserts 86 inasmuch as the ends thereof fitting within the end form 122 will be tapered in the same manner as is the end form 122. However, that portion of each of the inserts connecting together the pan 10 and the end form 122 disposed within the pan 10 will be identical with a similar portion of an insert 86.

Referring now to Figures 8 and 10 in particular, it will be seen that there is illustrated a still further modified form of end form which is referred to in general by the reference numeral 150. The end form 150 tapers towards its free end not only in width but also The end form 150 includes a generally channelshaped member 152 which has disposed therein and secured thereto a V-shaped reinforcing member 154. The reinforcing member 154 is secured to the channel-shaped member by a longitudinal row of fasteners such as staples 156.

The channel-shaped member 152 includes a generally trapezoidal web 158 which has disposed at the side edges thereof downwardly directed diverging flanges 160. The flanges 160 decrease in height toward the free end of the end form 150 and are provided at their lower edges with integral outwardly directed wings 162. The channelshaped member 152 also includes a downwardly and outwardly sloping end wall 164 which terminates in an outwardly directed flange 166 having apertures 168 therein for receiving fasteners adapted to secure the end form to a supporting frame. The end wall 164 also includes inwardly directed flanges 170 at its side edges which underlie the flanges 160 and are secured thereto by removable fasteners 172.

The reinforcing member 154 is similar to the reinforcing members 14 and 126 although the taper of the same is different. The reinforcing member 154 includes outwardly directed flanges 174 which underlie the wings 162 and are secured thereto by staples 125. The flanges are provided with apertures aligned with apertures 176 7 V of the wings 162 for the reception of fasteners adapted to secure the end form 150 to a supporting frame.

It will be understood that the cross section of the end form 150 at the end thereof in abutment with the pan 10 is identical with that of the pan 10. The end form 150 then decreases in height and width towards its free end.

It will be understood that the reinforcing member 154 in combination with the channel-shaped member 152 forms generally triangular spaces similar to the spaces 46 between the reinforcing member 14 and the channel shaped member 12 of the pan 10. It will be also understood that such spaces will be in alignment with the spaces 46 of the pan 10. The pan 10 is then secured to the end form 150 by a pair of inserts 178. The inserts 178 have one end thereof, that end disposed within the spaces 46 identical to one-half of the inserts 86. The other end of each insert 178 is tapered to fit within the corresponding spaces of the end form 150.

While the end forms 50, 122, and 150 are of slightly different shapes, it will be understood that by removing the fasteners 80, 144 and 172, respectively, each of the end forms may be flattened for shipment in the manner similar to that of pan 10, as is best illustrated in Figure 7. The end forms will then be formed in two separate sheets which are connected together along their longitudinal centers by rows of suitable fasteners such as the staples illustrated and described above. By providing end forms as well as pans which may be shipped in a flat state, it will be seen that the shipping charges for the improved form construction, which is the subject of this invention, is relatively slight as compared with conventional metal forms. Also, it will be seen that the forms will come in a relatively small package for storage purposes so as to save on warehouse space.

Not only are the forms of this invention easily stored and shipped at a relatively low cost but by constructing the same of relatively inexpensive fibrous material such as cardboard, the initial cost of the same in such that they may be disposable. The forms are reinforced in such a manner so as to have suflicient strength while at the same time being light in weight. Inasmuch as the pans and the end forms are light in weight, it will be seen that they may be easily and quickly placed due to the fact that they may be easily handled. This also results in lower total cost inasmuch as the labor cost for handling the forms will be greatly reduced.

It will be seen that by providing a novel form construction applicant has also provided a means for a novel floor construction and a novel method of forming a combined floor construction and ceiling.

From the foregoing, the construction and operation of the device will be readily understood and further explanation is believed to be unnecessary. However, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the appended claims.

What is claimed as new is as follows:

1. A disposable concrete form comprising a plurality of pans, each of said pans comprising an elongated channel-shaped member including a web and spaced flanges, a reinforcing member disposed Within said channel-shaped member and bracing said flanges relative to said web, said reinforcing member being generally 8 V-shaped and forming in combination with said web and flanges triangular tubular sleeve-like spaces, triangular cross sectional inserts disposed in ends of said sleevelike spaces joining adjacent pans together.

2. A disposable concrete form comprising a plurality of pans, each of said pans comprising an elongated channel-shaped member including a Web and spaced flanges, a reinforcing member disposed within said channel-shaped member and bracing said flanges relative to said web, said reinforcing member being generally V-shaped and forming in combination with said web and flanges triangular tubular sleeve-like spaces, triangular cross sectional inserts disposed in ends of said sleeve-like spaces joining adjacent pans together, end pans forming ends of said form, said end pans having cross sections identical to cross sections of said first-named pans and joined thereto by other inserts.

3. A disposable concrete form in the form of an elongated pan, said form comprising an elongated channel-shaped member including a web and spaced flanges, a first elongated sheet reinforcing member disposed within said channel-shaped member and bracing intermediate portions of said flanges relative to said web, a second elongated sheet reinforcing member disposed Within said channel-shaped member and bracing said flanges relative to said web, said flanges having outwardly directed wings, said reinforcing members being connected directly to said wings.

4. A disposable concrete form in the form of an elongated pan, said form comprising an elongated channel-shaped member including a web and spaced flanges, a first elongated sheet reinforcing member disposed within said channel-shaped member and bracing intermediate portions of said flanges relative to said web, a second elongated sheet reinforcing member disposed within said channel-shaped member and bracing said flanges relative to said web, said first reinforcing member being channel-shaped, said second reinforcing member being generally V-shaped, said flanges having outwardly directed Wings, said reinforcing members being connected directly to said wings.

References Cited in the file of this patent UNITED STATES PATENTS 1,160,384 Crane Nov. 16, 1915 1,168,627 Goldsmith Ian. 18, 1916 1,222,349 Baker Apr. 10, 1917 1,231,348 Hernandez June 26, 1917 1,239,503 Merrick Sept. 11, 1917 1,363,391 Carpenter Dec. 28, 1920 1,417,614 McAbee May 30, 1922 1,425,823 Baker Aug. 15, 1923 1,477,767 Pulis Dec. 18, 1923 1,892,311 MacDonald Dec. 27, 1932 1,897,530 Pandolfi Feb. 14, 1933 2,022,784 Rice Dec. 3, 1935 2,160,221 Masters et a1. May 30, 1939 2,286,817 Knight June 16, 1942 2,425,004 Rabell Aug. 5, 1947 2,444,183 Cahners June 29, 1948 2,447,677 Williams Aug. 24, 1948 FOREIGN PATENTS 107,875 Australia July 13, 1938 519,218 Great Britain Mar. 1.9, 1940 812,151 France May 1, 1937 

